Self-piercing riveting

ABSTRACT

A self-piercing rivet for forming joints in high strength steel has a partially hollow shank of a particular form in order to ensure that it has sufficient column strength to pierce the material. The thickness of the shank is such that adequate joint strength is achieved with a lower degree of flare than would be necessary for conventional riveted joints. The ratio of the thickness of the shank (outside diameter minus inside diameter) is in the range 0.47 to 0.52. The ratio of the cross sectional area of the shank in the region around the bore to the outside diameter of the shank is in the range 3.0:1 to 3.6:1

The present invention relates to a self-piercing rivet and moreparticularly to a self-piercing rivet of the kind that is inserted intosheet material without full penetration such that a deformed end of therivet remains encapsulated by an upset annulus of the sheet material.The invention also relates to a riveting method and a system for theinsertion of such a rivet.

Self-piercing rivets of the kind defined above, and methods andapparatus for inserting such rivets into sheet material are well known.

U.S. Pat. No. 6,385,843 discloses a self-piercing rivet that has provedcommercially successful. The rivet has a deep central bore with arounded base and a conical entrance having a generally curved surface.

U.S. Pat. No. 6,325,584 shows a partially hollow self-piercing rivet forjoining aluminium sheet. The rivet is specifically designed to be madeof light metal with low tensile strength and has a central bore that isshallow and conical. The piercing end of the rivet is as blunt aspossible in order to preclude the possibility of early deformationduring the insertion process. The rivet shank is compressedsignificantly in the finished joint.

DE 20319610U discloses a self-piercing rivet designed particularly forinsertion into high strength steel sheets. The rivet has a deep bore andis formed from a high strength material. The rivet has a particularconfiguration at the piercing end with a piercing edge disposed betweenthe inner and outer surfaces of the shank and disposed radially outsidethe middle of the shank. The inner surface, around the entrance to thebore, has a curved profile. The rivet shank is compressed significantlyin the finished joint.

A known self-piercing rivet is illustrated in FIGS. 1 and 2 of theaccompanying drawings. As shown in FIG. 1, the rivet 1 is partiallyhollow with a head 2 and a cylindrical shank 3 that terminates in anannular edge 4. As the rivet is driven into two overlapping sheets ofmaterial 5, 6 over a suitably shaped die (not shown), the shank iscaused to flare outwardly into the shape illustrated in FIG. 2. Thesheets of material 5, 6 are caused to deform around the shank, creatingan annulus that encapsulates the shank. The shank 3 and edge 4 of therivet remain embedded in the sheet material 5, 6 after the rivet hasbeen set. Self-piercing riveting enables sheet material to be joinedwithout the requirement for the pre-drilling or pre-punching of a holein the material.

Self-piercing riveting has been used to great success in the automotiveindustry where light-weight materials, such as aluminium, have beenadopted for vehicle body panels in the interests of weight reduction andtherefore reduced energy consumption. Aluminium is difficult or notfeasible to spot weld, particularly to steel, owing to its high thermalconductivity, low melting range and propensity to form oxide surfacefilm. Self-piercing rivets of the kind shown in FIGS. 1 and 2 have beenused in joining such panels with little visible distortion on theexposed panel surfaces. Since the lower sheet is not pierced there is areduced risk of corrosion occurring in the completed joint. Morerecently in the automotive industry there has been a move to using highstrength or ultra high strength steels, such as “Docol DP/DL” availablefrom SSAB Tunnplat AB in Sweden, which allow further weight reduction.It is desirable to be able to use self-piercing rivets in joints madewith high strength steel or indeed thick stack sheet steel withoutcompromising joint strength or introducing defects or corrosion points.The high strength/greater stiffness of this kind of sheet materialcombination makes this difficult in that the rivet experiences higherforces during the setting operation. Conventional self-piercing rivetsare not capable of withstanding these higher forces required to piercesuch materials in such a way that the rivet deforms in a controllablemanner to ensure that the final joint is satisfactory. Simply making therivet from higher strength material does not generally achieve thedesired results as the corresponding reduced ductility can causecracking of the shank as it attempts to flare during insertion. In orderto form a suitable joint with satisfactory strength and corrosionresistance, the shank of the rivet needs to have sufficient columnstrength to pierce the top sheet of material without buckling, but yetflare outwardly during insertion in a repeatable and predictable mannerwithout tearing or cracking in order to form a satisfactory joint.

One problem with steel is that, for a given grade, parameters such asstrength and ductility can vary between batches and betweenmanufacturing sources. It is therefore important that any rivet designshould be capable of accommodating such variations.

It is also desirable to have a rivet design that is capable of beingused with different combinations of thick and thin sheets.

A typical undesirable joint produced with a conventional self-piercingrivet is shown in FIG. 3. It will be appreciated from a brief inspectionthat the degree of flare of the shank is not symmetric around the rivet,the shank has been compressed and has buckled such that there is aclearance (A) between the shank and the sheets and there is separation(B) of the sheets. Cracking of the rivet shank is also evident (E).These all contribute to compromising of the joint strength, particularlydynamic strength. Other factors that are to be avoided are cracking ofthe rivet on the underside of the head (area C) and at the intersectionof the wall of the shank with the base of the bore (area D).

It is also desirable that the self-piercing rivet geometry is such thatit can be used with existing self-piercing riveting setters and feeders.This means that the diameter of the head of the rivet should beequivalent to that of existing rivets the setter and feeders aredesigned to handle. Moreover, riveted products are currently beingdesigned on the basis of existing rivet sizes taken from numerous designguidelines and references. Simply scaling up the rivet size is thereforenot a desirable solution.

It is an object of the present invention to obviate or mitigate this andother disadvantages and to provide for a self-piercing rivet that issuitable for use in joining high strength steel and/or thick stack steelsheet combinations.

According to a first aspect of the present invention there is provided aself-piercing rivet comprising a substantially cylindrical shank havingan outside diameter and a head, the shank having a central blind boredefining an inside diameter and an annular piercing end spaced from saidhead, characterised in that the ratio of the difference between theoutside and inside diameters of the shank in the region around the boreto the outside diameter of the shank is in the range 0.47 to 0.52.

The ratio of the cross sectional area of the shank in the region aroundthe bore to the outside diameter of the shank may be in the range 3.0:1to 3.6:1 and more preferably the ratio is 3.1:1.

The ratio of the diameter of the head to the outside diameter of theshank may be in the range 1.35:1 to 1.47:1 or may be 1.4:1.

The ratio of the effective length of the rivet to the depth of the boremay be in the range 1.56 to 2.4.

For a given length of rivet the ratio of the effective rivet length todepth of the bore has been found to be most effective if it is greaterthan compared to a rivet of conventional design. This enhances thestability of the rivet shank thereby reducing the tendency for the rivetto collapse and the tendency for asymmetric flaring of the shank duringrivet insertion.

The annular piercing end may have a first portion, which may besubstantially flat portion, and a second portion in the form of aconical taper that may define an included angle of substantially 90degrees. The first portion may define a surface that is generallydisposed such that it is inclined at an angle of between 0° and 10° tothe perpendicular to the central axis of the rivet (i.e. itslongitudinal axis)

An upper portion of the shank immediately below the head has atransition region forming a smooth intersection with the head. Thetransition region may have a radius of curvature in the range 0.8 to 1.2mm or 0.9 to 1.1 mm. Alternatively the transition region may have aradius of curvature of 1 mm.

The rivet may be made from typical fastener grade steel such as BS EN10263 and subsequently heat treated to a hardness of at least 350 Hv. Itmay alternatively be made from an aluminium alloy or stainless steel.The shank of the rivet may have an outside diameter of 5.5 mm and thecross sectional area of the shank in the region around the bore may be17.15 mm².

According to a second aspect of the present invention there is provideda self-piercing rivet comprising a substantially cylindrical shankhaving an outside diameter and a head, the shank having a central blindbore defining an inside diameter and an annular piercing end spaced fromsaid head wherein the annular piercing end has a substantially flatportion and a conical taper and the ratio of the length of the flatportion to the thickness of the shank is in the range 0.33 to 0.66.Alternatively it may be in the range 0.4 to 0.7:1 or 0.5 to 0.7:1.

According to a third aspect of the present invention there is provided aself-piercing rivet comprising a substantially cylindrical shank havingan outside diameter and a head, the shank having a central blind boredefining an inside diameter and an annular piercing end spaced from saidhead wherein the annular piercing end has a first portion radiallyoutboard of a second portion that is in the form of a conical taper andthe ratio of the length of the first portion to the thickness of theshank is in the range 0.4 to 0.7:1.

The ratio of the length of the first portion to the thickness of theshank may be 0.6:1.

The annular conical taper may define an included angle of substantially90 degrees.

According to a fourth aspect of the present invention there is provideda method for forming a joint in at least one high strength sheet steelhaving a UTS in the range 200 to 1400 MPa using a self-piercing rivetcomprising the steps of: positioning the sheet material over a die;providing a rivet having a substantially cylindrical shank and a head,the shank having a central blind bore and an annular piercing end spacedfrom said head, ratio of the thickness of the shank in the region aroundthe bore to the outside diameter of the shank is in the range 0.47 to0.52; positioning a rivet over the sheet material at a position oppositethe die; using a punch to set the rivet and force it into the sheetmaterial such that it pierces the upper surface thereof and such thatthe shank deforms outwardly to interlock with the material but withoutpenetration to the die side of the material.

According to a fifth aspect of the present invention there is provided amethod for forming a joint between at least one high strength sheetsteel having a UTS in the range 200 to 1400 MPa and a sheet of differentmaterial using a self-piercing rivet comprising the steps of:positioning the sheet material over a die; providing a rivet having asubstantially cylindrical shank and a head, the shank having a centralblind bore and an annular piercing end spaced from said head, ratio ofthe thickness of the shank in the region around the bore to the outsidediameter of the shank is in the range 0.47 to 0.52; positioning a rivetover the sheet material at a position opposite the die; using a punch toset the rivet and force it into the sheet material such that it piercesthe upper surface thereof and such that the shank deforms outwardly tointerlock with the material but without penetration to the die side ofthe material.

The total thickness of the stack of material being joined may be in therange 4 mm to 18 mm. The sheet of high strength steel may have athickness in the range 1 to 4 mm. Alternatively it may be no greaterthan 6 mm.

According to a sixth aspect of the present invention there is provided amethod for forming a joint in a plurality of sheets of material, thecombined thickness of the sheets being in the range 4 mm to 18 mm usinga self-piercing rivet comprising the steps of: positioning the sheetmaterial over a die; providing a rivet having a substantiallycylindrical shank and a head, the shank having a central blind bore andan annular piercing end spaced from said head, ratio of the thickness ofthe shank in the region around the bore to the outside diameter of theshank is in the range 0.47 to 0.52; positioning a rivet over the sheetmaterial at a position opposite the die; using a punch to set the rivetand force it into the sheet material such that it pierces the uppersurface thereof and such that the shank deforms outwardly to interlockwith the material but without penetration to the die side of thematerial.

According to a seventh aspect of the present invention there is provideda rivet insertion system comprising a punch for applying an insertionforce to a rivet, a die into which the material being riveted isdeformed and a rivet as defined above.

Specific embodiments of the present invention will now be described, byway of example only, with reference to the accompanying drawings inwhich:

FIG. 1 is a part-sectioned view showing a prior art self-piercing rivet;

FIG. 2 is a is a sectioned view showing a riveted joint in overlappingsheets of material made using the self-piercing rivet of FIG. 1;

FIG. 3 illustrates an undesirable self-piercing riveted joint;

FIG. 4 shows a first embodiment of a self-piercing rivet according tothe present invention;

FIG. 5 represents a section through the rivet of FIG. 4 along line A-A;

FIG. 5A is a close-up view of part of a piercing end of the rivet ofFIGS. 4 and 5 depicted alongside the corresponding part of a prior artrivet for comparison;

FIG. 6 is a close-up view of the area of the rivet labelled B in FIG. 5;

FIG. 7 is a second embodiment of a self-piercing rivet according to thepresent invention;

FIG. 8 is a sectioned view through the rivet of FIG. 7 along line A-A;

FIG. 9 is a part-sectioned view showing the rivet of FIGS. 4 to 6 readyfor insertion into sheet material using a punch and a die;

FIG. 10 is a section through a joint formed by inserting the rivet ofFIGS. 7 and 8 into sheet material using the punch and die of FIG. 9; and

FIGS. 11A is a photograph of a section cut through a riveted joint madein high strength steel with a first prior art rivet;

FIG. 11B is a photograph of a section cut through a riveted joint madein high strength steel with a second prior art rivet;

FIG. 11C is a photograph of a section cut through a riveted joint madein high strength steel with a rivet in accordance with the presentinvention;

FIG. 11D is a close up of part of the joint shown in FIG. 11A; and

FIG. 11E is a close up of part of the joint shown in FIG. 11B.

Referring now to FIGS. 4 to 6 of the drawings, the exemplaryself-piercing rivet 10 is substantially cylindrical with a head portion11 that extends radially outwards from a depending shank 12 that ispartially hollow so as to define a central bore 13. The shank has apiercing end 14 distal from the head.

The head portion 11 of the rivet 10 has a substantially constantdiameter of depth H that is integrally formed with an upper end of theshank 12 and a planar upper surface 15 to which a force is applied toinsert the rivet into the workpiece. The rivet is configured such thatin the final joint this upper surface 15 is substantially flush with thesurrounding surface of the workpiece. The upper end of the shank flaresoutwardly with a radius R1 to meet with the underside of the head. Thisradius R1 serves as a transition surface between the head 11 and theshank 13. The rivet has an overall length of H+L where H is the depth ofthe head and L is what is known as the effective length of the rivetwhich comprises the length of the transitional radius R1 in thedirection along the axis X of the rivet and the length of the shank 13.

The piercing end 14 of the rivet comprises an annular piercing edge 16that defines a flat surface extending in a plane substantially parallelto that occupied by the upper surface 15 of the head and a radiallyinboard conical taper 17 that extends inwardly to meet with the bore 13.The taper has an included angle of 90° that forms a transition betweenthe flat surface and the bore 13 in the shank 12. When viewed insection, as illustrated in FIG. 5A, the thickness of the flat surface oneach side of the section is L1, the length of the taper is L2 and theoverall thickness of the shank wall is L3. The inside surface 18 of theshank that defines the bore is of substantially constant diameterthroughout most of its length save for its base 19. The base 19 is veryslightly conical and there is an arcuate transition of radius R2 betweenthe periphery of the base 19 and the inside surface of the shank 18 asbest seen in FIG. 6.

In FIG. 5A the piercing end of the rivet is shown alongside that of acommercially available rivet (depicted on the left) of the correspondingsize and of the kind described in U.S. Pat. No. 6,385,843. In comparingthe two it will be noted that the piercing edge 16 is significantlylonger in the present rivet compared to the prior art rivet and theconical taper 17 is provided by a discrete surface rather than a curvedtransition into the bore. The exact form of the piercing edge 16 andconical taper 17 may vary. In particular, the piercing edge 16 may be inthe form of a surface that is not flat but is rather arcuate or convex.A suitable radius may be provided at the intersections between thepiercing edge 16 and the outside surface of the shank and/or the conicaltaper 17. Moreover, the surface defined by the piercing edge 16 need notnecessarily be disposed in a plane perpendicular to the central axis ofthe rivet but may be inclined at an angle in the region of up to 10° tothat plane.

It will be seen that the rivet has an upper solid portion defined by adistance W between the top surface 15 of the rivet head 11 and the base19 of the central bore 13 of the shank (see FIG. 5), and a hollowportion provided by the bore.

A table showing different possible values of effective rivet length Land the depth of the solid portion, W is shown below:

“L” “W” 5 2.5 6 3.0 7 3.0 8 3.5 9 4.5 10 5.5 11 6.5 12 7.5 14 9.5

In each case the transition radius R1 of the lower part of the head is1.0 mm and the transition radius R2 at the base of the bore is 0.4 mm.The transition radius R1 does not extend over a full 90° arc.

The alternative rivet design of FIGS. 7 and 8 differs only in the shapeof the head. In this embodiment, the head 20 in larger and is designedto stand proud from the workpiece into which it is inserted. The uppersurface 21 of the head has a planar central portion and an arcuatelytapered periphery 22. For this rivet type, examples of the measurementsL and W are shown in the table below:

“L” “W” 5 3.5 6 4.0 7 4.0 8 4.5 9 5.5 10 6.5 11 7.5 12 8.5 14 10.5

In each case the transition radius R1 at the head is 1.0 mm and thetransition radius R2 in the bore is 0.4 mm.

For each of the rivet embodiments, the thickness or the cross-sectionalarea of the shank in the region where it is hollow is greater for therivet of the present invention than compared to that of a conventionalself-piercing rivet. This provides an improvement in the column strengthof the rivet shank providing greater resistance to the onset ofcompression or buckling. However, it has been determined that theprecise thickness needs to be carefully controlled in order to avoidboth insufficient and excess flaring of the shank and thereby ensurethat the rivet is capable of forming good quality joints in highstrength steel. Moreover, it has been realised that the best results areobtained with a rivet in which the greater shank thickness in comparisonto corresponding prior art rivets is achieved by increasing the outsidediameter of the shank (without a corresponding increase in the diameterof the rivet head) rather than decreasing the inside diameter.

It has been found that the length of the flat surface L1 should berelatively short in comparison to the thickness of the shank in orderfor the rivet to be suitable for riveting high strength steel or thickstack steel a ratio of L1:L3 in the range 0.33 to 0.66 produces the bestresults. Preferably the ratio L1:L3 is 0.5 or 0.6.

In one example, the shank of the rivet of FIGS. 4 to 6 or FIGS. 7 and 8has an outside diameter Do of 5.5 mm and an inside diameter Di of 2.9mm. This results in the difference between the diameters (Do minus Di)being 2.6 mm. The ratio of this difference (i.e. twice the shankthickness) to the outside diameter is therefore 0.473. This compares toa ratio in the range of 0.340 to 0.437 for conventional rivet designs ofa comparable size. The cross-sectional area of the shank in this regionis 17.15 mm². A comparable conventional rivet has a cross-sectional areaof no larger than 14.2 mm². It is anticipated that in the presentinvention the ratio of the shank thickness to outside diameter can beincreased to 0.517 without impairing the ability of the shank to flaresufficiently. The cross-sectional area may be in the range 16.0 mm² to22.0 mm². The ratio of the cross-sectional area of the shank (in thehollow region) to the outside diameter of the rivet is 3.1:1 whichcompares to a ratio of 2.4:1 to 2.8:1 in prior art rivets of this kind.The head of the rivet has a diameter of 7.75 mm and this ensures thatthe rivet is small enough to be used with existing rivet setting andfeeding equipment and is consistent with design guidelines for the spacerequired for the rivet and the access of the application tooling. Theratio of the diameter of the rivet head to the outside diameter of theshank is 1.4:1. This compares to a ratio of 1.5:1 for conventionalself-piercing rivets.

The rivet is preferably made from a medium carbon manganese-boron steele.g. conforming to British Standard BS EN 10263 that has been heattreated in a conventional manner to achieve a hardness of at least 350Hv. Alternatively, the self-piercing rivet could be made from aluminiumalloy of the 7000 series or from stainless steel.

FIG. 9 shows the rivet 10 of FIGS. 4 to 6 held in the nose 30 of a rivetsetter by centring elements 31 (e.g. a plurality of spring centringballs) ready for insertion into overlapping sheets 32, at least one ofwhich is material of the type mentioned need to clarify this statement.The rivet setter comprises a clamping ring 33 and a punch 34 by whichthe rivet is inserted. The rivet setter may be hydraulically orelectrically actuated. The sheet material 32 is supported over a die 35opposite the punch and may first be clamped before the punch inserts therivet in accordance with the method described in our U.S. Pat. No.5,752,305, the content of which is incorporated herein by reference. Asthe rivet is inserted the material deforms into a suitably shaped cavity36 in the die.

FIG. 10 shows a completed joint in which the rivet of FIGS. 7 and 8 hasbeen inserted into overlapping sheets of high strength steel ofrelatively low ductility with an ultimate tensile strength (ITS) ofapprox. 600 Mpa, both sheets having a thickness of 2.6 mm. An insertionforce of 47 kN was used. It can be seen that the deformation of therivet shank is substantially uniform around the rivet and there is nobuckling. The degree of flare of the shank and the undercut in thebottom sheet is sufficient to provide satisfactory mechanical propertiesof the joints. A visual inspection will show that there is nosignificant separation of the sheets from one another and no clearancebetween the outside of the shank and the sheets which indicates that thejoint will exhibit satisfactory dynamic performance. The thicker shankof the rivet in comparison to its outside diameter improves the columnstrength such that the rivet can withstand the high forces required topierce and form the joint in the high strength steel. However, it hasbeen established that the increased thickness must be selected carefullyin relation to the outside diameter as it is a factor in ensuring thatthe rivet shank has the capacity to flare outwardly during insertion andto provide sufficient interlock with the sheets when upset in a suitabledie. It has been realised that for high strength steels or thick stackjoints adequate joint strength is achieved with a lower degree of flarethan would be necessary for conventional riveted joints.

The thicker shank and the depth W are selected to ensure that the rivetis not compressed in height significantly during the rivet insertionoperation and will be discernable from an inspection of FIG. 10.

The radii on the outside and inside of the shank are designed towithstand the initiation of cracking and are greater than forconventional rivets. When a self-piercing rivet is inserted by a punchthere is a reaction force such that the rivet tends to spring backproducing high tensile forces in the areas described above.

It has been determined that the rivet is particularly suitable forjoining high strength steels having an ultimate tensile strength in therange 200 to 1400 MPa, the total thickness of the stack being in therange 2.5 to 7 mm and no sheet being greater than 4 mm in thickness. Insome tests successful joints have been achieved in a stack thickness of8 mm. The joint may comprise such a rivet used to join a single sheet ofthis type to any other type of sheet material suitable for riveting, inwhich case the total thickness of the sheet stack is in the range 4 to18 mm. Similarly the rivet is suitable for joining thick stacks of moreconventional sheet materials in which the total thickness of the stackis between 4 mm and 18 mm.

It is considered that a satisfactory riveted joint of the kind shown inFIG. 10 cannot be made with any conventional rivet designs.

Tests were conducted on two prior art rivets and a rivet embodying thepresent invention and the results, depicted in FIGS. 11A to 11E,illustrate the benefits of the present invention.

In all three cases the tests were performed by inserting a hardenedsteel rivet into overlapping high strength steel sheets having anultimate tensile strength of 600 MPa and a thickness of 2.6 mm. Eachrivet has the same head diameter (7.75 mm) and effective length (7.0 mm)and is upset using a Henrob die (part number DF10-250) and applying aclamping force of 100 bar both before and during rivet insertion. Allthree rivet types were hardened using a conventional in-line continuousprocess comprising the steps of subjecting the rivet to an austenisingheat treatment, a rapid oil quench and tempering to achieve a finalhardness in the range 530-580 Hv and a tensile strength of approximately1900 MPa.

In FIGS. 11A and 11D the prior art rivet (Henrob rivet type K50746P) hasa shank with an outside diameter of 5.3 mm and an inside diameter of 3.2mm giving a ratio of shank thickness to outside diameter of 0.4:1. Itcan be seen that the rivet has insufficient column strength resulting incollapse and fracture (indicated by arrows A) in the finished joint.Moreover, premature and/or excessive flaring of the end of the shank hascaused gaps (one example indicated by arrow B) to appear between theshank and the sheets.

In FIGS. 11B and 11E the prior art rivet (Henrob rivet type P50746) hasa shank with an outside diameter of 5.1 mm and an inside diameter of 2.9mm. The ratio of the thickness of the shank to the outside diameter is0.43. Despite the shank being thicker than that of the rivet of FIG.11A, it is clear from the finished joint that it has insufficient columnstrength that has lead to partial collapse and fracture (see arrow C).Again sheet to shank gaps are apparent (one example indicated by arrowD) as a result of premature or excessive flaring.

In FIG. 11C a rivet embodying the present invention has a shank with anoutside diameter of 5.5 mm, an inside diameter of 2.9 mm (giving a shankthickness to outside diameter ratio of 0.47) and a tip geometry asdepicted in FIG. 5A. It can be seen that the rivet has sufficient columnstrength to pierce the top sheet and penetrate into the bottom sheetwithout collapse. Moreover, the geometry is such that premature orexcessive flaring of the end of the shank is prevented as evidenced bythe lack of fracturing, but the ductility is sufficient to allowinterlock with the lower sheet. In particular the geometry of the rivetensures that the shank only starts to flare once it has penetrated theupper sheet such that there are no significant gaps between the sheetsand the shank. The final joint has sufficient interlock between therivet and the sheets to provide satisfactory mechanical properties.

Through its enhanced column strength and geometry, the rivet of thepresent invention is designed to tolerate the variations in strengthcharacteristics in steel of a given grade in industry.

It is to be understood that the rivet of the present invention may beused to join both thin and thick sheet combinations.

It will be appreciated that numerous modifications to the abovedescribed design may be made without departing from the scope of theinvention as defined in the appended claims. For example, the rivetdesign may be realised in an alternative material, may be used to joinmore than two sheets, may be applied to other materials or may beadapted to include a threaded stud formed on its head for insertion intoa single sheet

1. A self-piercing rivet comprising a substantially cylindrical shankhaving an outside diameter and a head, the shank having a central blindbore defining an inside diameter and an annular piercing end spaced fromsaid head, characterised in that the ratio of the difference between theoutside and inside diameters of the shank in the region around the boreto the outside diameter of the shank is in the range 0.47 to 0.52.
 2. Aself-piercing rivet according to claim 1, wherein the ratio of the crosssectional area of the shank in the region around the bore to the outsidediameter of the shank is in the range 3.0:1 to 3.6:1.
 3. A self-piercingrivet according to claim 2, wherein the ratio of the cross-sectionalarea of the shank in the region around the bore to the outside diameterof the shank is 3.1:1.
 4. A self-piercing rivet according to claim 1,wherein the ratio of the diameter of the head to the outside diameter ofthe shank is 1.4.
 5. A self-piercing rivet according to claim 1, whereinthe ratio of the diameter of the head to the outside diameter of theshank is in the range 1.35 to 1.47:1.
 6. A self-piercing rivet accordingto claim 1, wherein the ratio of the effective length of the rivet tothe depth of the bore is in the range 1.56 to 2.4.
 7. A self-piercingrivet according to claim 1, wherein the annular piercing end comprises afirst portion that is radially outboard of a second portion, the secondportion being a conical taper intermediate the first portion and thebore.
 8. A self-piercing rivet according to claim 7, wherein the firstportion defines a surface that is generally disposed such that itextends substantially perpendicular to a central axis of the rivet.
 9. Aself-piercing rivet according to claim 7, wherein the first portiondefines a surface that is generally disposed such that it is inclined atan angle of between 0° and 10° to the perpendicular to the central axis.10. A self-piercing rivet according to claim 7, wherein the surfacedefined by the first portion is substantially flat.
 11. A self-piercingrivet according to claim 7, wherein the surface defined by the firstportion is arcuate.
 12. A self-piercing rivet according to claim 7,wherein the first portion is inclined to a central axis of the rivet ata shallower angle than the second portion.
 13. A self-piercing rivetaccording to claim 7, wherein the annular conical taper defines anincluded angle of substantially 90 degrees.
 14. A self-piercing rivetaccording to claim 7, wherein the ratio of the length of the firstportion to the thickness of the shank is in the range 0.33 to 0.66:1.15. A self-piercing rivet according to claim 7, wherein the ratio of thelength of the first portion to the thickness of the shank is in therange 0.4 to 0.7:1.
 16. A self-piercing rivet according to claim 7,wherein the ratio of the length of the first portion to the thickness ofthe shank is in the range 0.5 to 0.7:1.
 17. A self-piercing rivetaccording to claim 7, wherein the ratio of the length of the firstportion to the thickness of the shank is substantially 0.5:1.
 18. Aself-piercing rivet according to claim 7, wherein the ratio of thelength of the first portion to the thickness of the shank issubstantially 0.6:1.
 19. A self-piercing rivet according to claim 1,wherein the head has an upper portion and a transition region definedbetween the upper portion and the shank, the transition region having aradius of curvature in the range 0.8 mm-1.2 mm.
 20. A self-piercingrivet according to claim 1 where the head has an upper portion and atransition region defined between the upper portion and the shank, thetransition region having a radius of curvature of substantially 1 mm.21. A self-piercing rivet according to claim 1, wherein the bore isdefined by a substantially cylindrical surface, that is concentric withthe outside surface of the shank, and a base surface, there being atransition region between the cylindrical surface and the periphery ofthe base surface, the transition region having a radius of curvature of0.4 mm.
 22. A self-piercing rivet according to claim 1, wherein the boreis defined by a substantially cylindrical surface, that is concentricwith the outside surface of the shank, and a base surface, there being atransition region between the cylindrical surface and the periphery ofthe base surface, the transition region having a radius of curvature ofgreater than 0.3 mm.
 23. A self-piercing rivet according to claim 1 andmade from medium carbon steel containing manganese and boron.
 24. Aself-piercing rivet according to claim 1, wherein the rivet isheat-treated to a hardness of at least 350 Hv.
 25. A self-piercing rivetaccording to claim 1, wherein the shank of the rivet has an outsidediameter of 5.5 mm and the cross sectional area of the shank in theregion around the bore is greater than 16.5 mm².
 26. A method forforming a joint in at least one high strength sheet steel having a UTSin the range 200 to 1400 MPa using a self-piercing rivet comprising thesteps of: positioning the sheet material over a die; providing a rivethaving a substantially cylindrical shank and a head, the shank having acentral blind bore and an annular piercing end spaced from said head,ratio of the thickness of the shank in the region around the bore to theoutside diameter of the shank is in the range 0.47 to 0.52; positioninga rivet over the sheet material at a position opposite the die; using apunch to set the rivet and force it into the sheet material such that itpierces the upper surface thereof and such that the shank deformsoutwardly to interlock with the material but without penetration to thedie side of the material.
 27. A method according to claim 26, used tojoin a plurality of sheets of such material, the rivet penetrating theuppermost sheet and deforming so as to join all of the sheets together,but not penetrating the lowermost sheet at least.
 28. A method accordingto claim 26, wherein the total thickness of the sheets being joined isin the region 2.5 to 7 mm.
 29. A method according to claim 26, whereinthe total thickness of the sheets being joined is in the region 2.5 to 8mm.
 30. A method according to claim 26, wherein the, or each, sheet ofmaterial has a thickness of no greater than 4 mm.
 31. A method accordingto claim 26, wherein the, or each, sheet of material has a thickness ofno greater than 6 mm.
 32. A method according to claim 26, wherein therivet material is aluminium or aluminium alloy.
 33. A method for forminga joint between at least one high strength sheet steel having a UTS inthe range 200 to 1400 MPa and a sheet of different material using aself-piercing rivet comprising the steps of: positioning the sheetmaterial over a die; providing a rivet having a substantiallycylindrical shank and a head, the shank having a central blind bore andan annular piercing end spaced from said head, ratio of the thickness ofthe shank in the region around the bore to the outside diameter of theshank is in the range 0.47 to 0.52; positioning a rivet over the sheetmaterial at a position opposite the die; using a punch to set the rivetand force it into the sheet material such that it pierces the uppersurface thereof and such that the shank deforms outwardly to interlockwith the material but without penetration to the die side of thematerial.
 34. A method according to claim 33, wherein the totalthickness of the stack of material being joined is in the range 4 mm to18 mm.
 35. A method according to claim 33, wherein the sheet of highstrength steel has a thickness in the range 1 to 4 mm.
 36. A methodaccording to claim 33, wherein the sheet of high strength steel has athickness in the range 1 to 6 mm.
 37. A method for forming a joint in aplurality of sheets of material, the combined thickness of the sheetsbeing in the range 4 mm to 18 mm using a self-piercing rivet comprisingthe steps of: positioning the sheet material over a die; providing arivet having a substantially cylindrical shank and a head, the shankhaving a central blind bore and an annular piercing end spaced from saidhead, ratio of the thickness of the shank in the region around the boreto the outside diameter of the shank is in the range 0.47 to 0.52;positioning a rivet over the sheet material at a position opposite thedie; using a punch to set the rivet and force it into the sheet materialsuch that it pierces the upper surface thereof and such that the shankdeforms outwardly to interlock with the material but without penetrationto the die side of the material.
 38. A self-piercing rivet insertionsystem comprising a punch for applying an insertion force to a rivet, adie into which the material being riveted is deformed and a rivet asclaimed in claim
 1. 39. A self-piercing rivet comprising a substantiallycylindrical shank having an outside diameter and a head, the shankhaving a central blind bore defining an inside diameter and an annularpiercing end spaced from said head, characterised in that the ratio ofthe difference between the outside and inside diameters of the shank inthe region around the bore to the outside diameter of the shank is inthe range 0.47 to 0.52, wherein the annular piercing end comprises afirst portion that is radially outboard of a second portion, the secondportion being a conical taper intermediate the first portion and thebore.
 40. A self-piercing rivet according to claim 39, wherein the firstportion defines a surface that is generally disposed such that itextends substantially perpendicular to a central axis of the rivet. 41.A self-piercing rivet according to claim 39, wherein the first portiondefines a surface that is generally disposed such that it is inclined atan angle of between 0° and 10° to the perpendicular to the central axis.42. A self-piercing rivet according to claim 39, wherein the surfacedefined by the first portion is substantially flat.
 43. A self-piercingrivet according to claim 39, wherein the surface defined by the firstportion is arcuate.
 44. A self-piercing rivet according to claim 39,wherein the first portion is inclined to a central axis of the rivet ata shallower angle than the second portion.
 45. A self-piercing rivetaccording to claim 39, wherein the annular conical taper defines anincluded angle of substantially 90 degrees.
 46. A self-piercing rivetaccording to claim 39, wherein the ratio of the length of the firstportion to the thickness of the shank is in the range 0.33 to 0.66:1.47. A self-piercing rivet according to claim 39, wherein the ratio ofthe length of the first portion to the thickness of the shank is in therange 0.4 to 0.7:1.
 48. A self-piercing rivet according to claim 39,wherein the ratio of the length of the first portion to the thickness ofthe shank is in the range 0.5 to 0.7:1.
 49. A self-piercing rivetaccording to claim 39, wherein the ratio of the length of the firstportion to the thickness of the shank is substantially 0.6:1.